Felting needle and method of making the same



Dec. 25, 1945. E. P. FOSTER FELTING NEEDLE AND METHOD OF MAKING THE SAME Filed Jan. 3, 1944 2 Sheets-Sheet l DIRECTION OF TRA VEL Q 1 MI in E OF CON VEYOR.

INVENTOR. Edam P1 56597:

Dec. 1945- E. P. FOSTER 2,391,560

FELTING NEEDLE AND METHOD OF MAKING THE SAME Filed Jan. 3, 1944 2 Sheets-Sheet 2 INVENTOR.

E dJOH/F 1 0.5152: BY 1m bw. Jazz! 10M Patented Dec. 25, 1945 FELTING NEEDLE AND METHOD OF MAKING THE SAME Edson P. Foster, Manitowoc, Wis., assignor to Adeline P. Foster, Torrington, Conn.

Application January 3, 1944, Serial No. 516,871

18 Claims.

The present invention relates to an improvement in a felting needle and the method of making the same.

Felting machines are well known and are employed for matting and compacting loose fibrous material, such as wool, hair and fur, or a combination of these or other analogous material, and frequently during the matting and compacting of the fibrous material it is simultaneously interlaced or interwoven with a web or fabric base. It is the general practice in the art to deliver the fibrous material to be compacted and the web or fabric to which it is to be interlaced or interwoven upon a slowly moving endless belt conveyor above which a two-part needle plate, having a large number of felting needles secured therein, is disposed. This plate is mounted for rapid vertical reciprocatory movement, above the conveyor belt. The felting needles referred to have barbs on the body portions thereof, which upon downward movement of the plate with respect to the conveyor, engage the fibers of the material and function to interlace the fibers together and the compacted and interlaced fibers to the web or base fabric. The barbs are so formed as to free themselves of the material upon upward movement of the plate. Upon continued repetition of the upward and downward movement of the plate the fibers of the fibrous material are compacted and interlaced with each other and with the web or fabric to form a mat. Machines of the type referred to may be suitably designed so that any desired degree of compacting and matting of the fabric material, within limits, may be obtained. Generally, the needle plate for supporting the felting needles comprises a base member and superimposed clamping member. The base member is provided with a suitable number of apertures through which the needles are inserted. The needles are provided wi.h securing elements which are adapted to seat upon the top surface of the base member. The clamping member and base member are then bolted or otherwise secured together rigidly clamping between them the securing elements at the upper ends of the needle shanks.

Felting needles are well known in the art and several different forms of barbs or spurs have been proposed and are in .use. Generally, it has been the accepted practice to provide a, plurality of barbs or spurs in' the body of a needle which may be of triangular or other polygonal cross section Or of circular cross section. Ithas been the practice to provide a plurality of barbs or spurs in the several corner edges of the needles of polygonal cross-section section and about the periphery of the body of needles of circular crosssection. This, however, is disadvantageous in that in interlacing or interweaving the fibrous material with the web or fabric, the indiscriminate arrangement of the barbs or spurs around all parts of the needle frequently fractures the warp and woof threads of the web which'greatly reduces the mechanical strength of the completed mat.

It is an object of my invention to provide a felting needle formed with a ridge extending generally lengthwise of the body portion of the needle and in which the barbs or spurs are all formed.

Preferably, the felting needle of my present invention is formed by forcing aningot of suitable material through a'forming die or other suitable apparatus to form wire having a ridge extending generally lengthwise thereof. Preferably the forming die is of a design so that the side walls and end wall of the ridge are curved. After the wire with the aforesaid ridge has been formed, the spurs may be made by forming a plurality of recess in the ridge extending transversely thereof to define a working surface at each recess. In the preferred form of my invention, the side walls of the ridge are preferably of alternate convex and concave surfaces with the end wall having a convex surface joining the convex surfaces of the side walls. Upon formation of a recess in a ridge of this character, it will be observed that a working surface for a spur is provided in which there are no straight line portions in the perimeter of the working surface since it is defined by the convex and concave surfaces of the side walls and the convex surface of the end wall of the ridge.

Other objects and advantages of my invention will appear from the detail description.

Now, in order to acquaint those skilled in the art with the manner of utilizing my invention, I shall describe in conjunction with the accompanying drawings certain preferred embodiments of the same.

In the drawings:

Figure 1 is a diagrammatic side view of a known form of felting machine, illustrative of the use of the needles of my present invention;

Figure 2 is a greatly enlarged elevational view of the needle of my invention disposed in a'body of fibrous material being interlaced and a web to which the fibrous material is being interwoven, with the felting needle mounted in a sleeve secured in the needle plate of a felting machine, the

sleeve being shown in section, and the needle plate being shown fragmentarily and in section;-

Figure 3 is a detail horizontal sectional view taken substantially on the line 3-4 of Figure 2;

Figure 4 is a diagrammatic view showing the manner in which wire stock from which needles of the present invention are constructed, is formed;

Figure 5 is a detail vertical sectional view, on an enlarged scale, taken substantially on the line 3-3 of Figure 4;

Figure 6 is a diagrammatic plan view of an apparatus for cutting the wire stock formed by the step illustrated in Figure 4 to form the working surfaces for the spurs of a felting needle;

Figure 7 is a detail horizontal sectional view.

taken substantially on the line 1-1 of Figure 2; and

Figure 8 is a detail horizontal sectional view taken substantially on the line 3-3 of Figure 6 looking in the direction indicated by the arrows.

Referring now to the drawings, I have illustrated diagrammatically in Figure 1 a known form of felting machine I, in which the needles of my present invention may be used, Loose fibrous material such as wool, fur, hair or the like, indicated at 2, is fed together with a suitable web or base fabric 3 by means of a suitable chute 4 onto an endless belt conveyor 5, which is trained over a pair of wheels 3 mounted for rotation on shafts I, one of which may be driven in any suitable known manner.

- A two-part needle plate 3, adapted to be reciprocated in any suitable manner, is disposed above the conveyor belt I.

Felting needles 3 are suitably fixed in the needle plate and serve to contact and interlace the fibrous material 2 together, and interlace the same with the web or fabric 3 upon the upper run of belt 5, in the reciprocation of the needle plate, as previously stated. A second conveyor I0, adjacent the discharge end of the conveyor 5 receives the completed mat and conveys it away from the conveyor 5.

In Figure 2 I have shown a felting needle Ii embodying my invention mounted in the needle plate 3 of a felting machine. This plate comprises a base member I2 and a clamping member l3. The base is apertured to receive a cylindrical sleeve l4, one end of which rests upon the upper surface of the base member i2. It will be understood that if desired the base member [2 may be countersunk to receive the flange of sleeve I4. However, it will be understood that if desired the sleeve l4 may be dispensed with and the needle ll may be disposed directly in the base member l2. The needle ll comprises a body portion I5 and a shank portion [6. The lower end of body I5 is pointed at I! to facilitate penetration of the fibrous material 2 and the web 3. The upper portion of shank [6 may be bent at substantially right angles providing a securing element 13 adapted to be clamped between clamping member l3 and base member 12 of the needle plate and in engagement with the flange of sleeve 14. When the sleeve I4 is desired to be used to strengthen and protect the needle against breakage, it will be understood that it should snugly receive the shank of the needle.

Referring now to Figures 4 and 5, I have shown diagrammatically an apparatus for forming wire stock from which the felting needles I I of my invention may be readily formed. An ingot 20 of suitable metal. such as steel, is forced by a ram 2| through a forming die 22 to form the ingot asoasoo into the wire 23. The forming die is of a character to form a lengthwise extending ridge 24 in the wire 23 which ridge 24, it will be observed, comprises side walls 25 formed by a into the cylindrical surface 34 of the wire. As

shown more clearly in Figures 3, 5 and 'I, the

formed wire stock comprises a body portion conforming in cross section to the segment of a circle, somewhat greater than a semi-circle, having a flat side or chordal surface, with a ridge or rib shaped as shown disposed centrally thereof and extending outward from and lengthwise of the body portion, and the needle Ii is of similar form. The wire may, within the broader aspects of my invention, be shaped to the desired form in any suitable manner.

After the wire 23 has been formed it is then mounted in a pair of clamp members or chucks 32 forming a part of a cutting apparatus indicated at 33 in Figure 6. A plurality of cutting tools 34 are suitably fixed in an operating head 35 mounted upon a base or guide member 38 for movement thereon. The clamps 32 are adapted to hold the wire 23 with the ridge 24 thereof in position to be out by the tools 34. The tools 34 are suitably shaped to form substantially V-shaped notches 3'! in the ridge 24 of the wire stock 23 by movement of the operating head 35 upon the base 36 transversely of the ridge and in a direction upwardly of Figure 6 as viewed in the drawings. The tools 34 are each formed with two cutting portions, the first or leading portion of which is serrated and tapers upward, as viewed in Figure 6, and the end or trailing portion of which is shown in section in Figure 8. The tools 34 are suitably spaced in head 35 to provide a plurality of V-shaped notches along the ridge 24 and suitable means (not shown) is provided for holding the wire between the chucks 32 against the pressure of the cuttin tools, as is known.

The stock as thus formed may then be cut oil in appropriate lengths to be pointed at one end as at I! and turned at its other end to form the securing elements l8 previously described. In the embodiment shown the tools have been spaced to form four equally spaced spurs in the ridge 24 of the needle shown at I I in Figure 2 in a single operation of the head 35.

Referring now to Figures 2 and 3, it will be seen that the felting needle I I has been provided with four spurs 38 in the ridge 24 thereof in the manner described above. The spurs 38 each comprise a working. surface 39 having no straight line portion (Figure 7) and in which the perimeter thereof is defined by the lower edges of the concave and convex surfaces 26 and 21, respectively, of the side walls 25, and the lower edge of the convex surface of the end wall 28.

The working surface 39 is shown as extending upwardly in a direction inwardly of the body of the needle, but it will be understood that the cutting step, previously described could be readily modified to form a working surface to extend at and the web 3 are moving in a direction toward the spurs of the needle. As shown the web or fabric '3 comprises a plurality of warp threads 40, and a plurality of woof threads 4| extending transversely of the warp threads and interlaced therewith. The needle I I in position B is mounted so that its barbs face away from the conveyor motion. The needle I I indicated at position C has its barbs disposed in angular relation to both the warp and woof threads 40 and 4|. In the three positions of the needles indicated, the needle in position A may on occasion cause fracturing of the woof threads 40. If complete assurance against injury of the web 3 is desired the needles may be arranged in the position indicated at B. The needles positioned as indicated at C would also cause less injury than the needles occupying position A. However, it will be observed that needles in position A would do more punching than needles in position. C, and the latter more than needles in position B due to the fact that the conveyor 5 carries the fibrous material 2 and web 3 into the barbs that face the direction of travel of the conveyor. In practice, in most instances. the needles would be arranged indiscriminately which for all practical purposes would not unduly damage the web due to the fact that the barbs of each needle are along a common longitudinal ridge.

While I have shown what I consider to be the preferred embodiment of my invention, it will be understood that various modifications and rearrangements may be made therein without departing from the spirit and scope of the invention I claim:

1. As a new article of manufacture, a felting needle having a body portion provided with a spur, said spur being formed by side walls extending generally lengthwise of said body, said side walls having alternate concave and convex surfaces with their lower edges spaced apart, and an end wall extending generally lengthwise of said body, said end wall having a convex surface with the lower edge of the end wall joining the lower edges of the convex surfaces of said side walls.

2. As a new article of manufacture, a felting needle having a body provided with a spur, said spur being formed by side walls extending generally lengthwise of said body, said side walls having alternate concave and convex surfaces with their lower edges spaced apart, and'an end wall extending generally lengthwise of said body, said end wall having a curved surface with its lower edge joining the lower edges of the curved surfaces of said side walls.

3. As a new article of manufacture, a felting needle having a body portion provided with a recess therein, a spur above said recess, said spur being formed by side walls extending generally lengthwise of said body, said side walls having alternate concave and convex surfaces with their lower edges spaced apart, and an end wall extending generally lengthwise of said body, said end wall having a convex surface with its lower edge jdining the lower edges of the convex surfaces of said side walls.

4. As a new article of manufacture, a felting needle comprising a body portion having a ridge extending generally lengthwise thereof, said ridge having curved side walls, and a curved end wall joining said side walls, and a recess in said ridge extending transversely thereof to provide a working surface the outer edges of which are defined by said curved side and end walls.

5. .As a new article of manufacture, a felting needle comprising a body portion having a ridge extending generally lengthwise of said body, said ridge having curved side walls with their lower edges spaced apart, and a curved end wall with its lower edge joining the lower edges of said side wall, and a plurality of recesses extending transversely of said ridge forming working surfaces therein with the outer edges of said working surfaces being defined by the curved surfaces of said side walls and said end wall.

6. As a new article of manufacture, a felting needle comprising a body portion having a ridge extending generally lengthwise thereof, said ridge comprising side walls having alternate concave and convex surfaces with their lower edges spaced apart, and an end wall having a convex surface with its lower edge joining the lower edges of said side walls defining a working surface at one end of the ridge. g

7. As a new article of manufacture, a felting needle comprising a body portion having a ridge extending generally lengthwise thereof, said ridge being formed by alternate concave and convex side walls, and an end'wall being formed by a convex surface and a plurality of recesses extending transversely of said ridge forming a plurality of working surfaces for the needle with the outer edges of said working surfaces being defined by the concave and convex urfaces of said side walls and the convex surface of said end wall.

8. The method of making a felting needle which comprises forming an ingot ir. wire having a ridge extending generally lengthwise thereof with said ridge having. curved side and end walls, and forming a spur in the ridge by cutting a recess transversely thereof to define a working surface for the spur at the junction of the edges of the side and end walls.

9. The method of making a felting needle which comprises, forming an ingot into wire having a ridge extending generally lengthwise thereof with the ridge having side walls formed by alternate concave and convex surfaces, and an end wall having a convex surface, and forming a spur in the ridge by cutting a recess in the ridge transversely thereof to define a working surface for the spur at the junction of the edges of the side and end walls.

10. As a new article of manufacture, a felting needle comprising a body portion of substantially segmento-circular cross section and a ridge extending lengthwise of said body portion between the ends of the arc thereof, said ridge having transverse recesses therein providing spurs having work engaging surfaces defined by the edges of said ridge at the respective recesses.

11. As a new article of manufacture, a felting needle comprising a body portion of approximately semi-circular cross section with a flat chordal side extending between. the ends of its arc and a ridge extending lengthwise of said fiat side having transverse recesses therein providing spurs having work engaging surfaces defined by the edges of said ridge at the respective recesses.

12. As a new article of manufacture, a felting needle comprising a body portion of approximately semi-circular cross section with a fiat chordal side extending between the ends of its arc and a ridge of generall quadrangular cross section extending lengthwise of said flat side having transverse recesses therein providing spurs having work engaging surfaces defined by the edges of said ridge at the respective recesses.

13. As a new article of manufacture, a feltin needle comprising a body of substantially uniform cross section and a ridge extending lengthwise of said body having side walls and an outer end wall joining said side walls, said ridge having transverse recesses therein providing spurs projecting outward beyond said body and having work engaging surfaces substantially conforming to the cross section of said ridge.

14. As a new article of manufacture, a felting needle comprising a body of substantially uniform cross section and a ridge extending lengthwise of said body projecting outward beyond the outline thereof and having side wall and an outer end wall joining said side walls, said ridge having transverse recesses therein providing spurs projecting outward beyond said body and having work engaging surfaces substantially conform-' ing to the cross section of said ridge.

15. As a new article of manufacture, a felting needle comprising a body portion having a generally lengthwise ridge of appreciable width and spaced apart recesses at opposite sides of said ridge, the latter having side walls joined by an outer end wall and being provided with transverse recesses forming spurs in said ridge.

16. As a new article of manufacture, a felting needle having a spur provided with a working en- 8 8111: surface defined by side edges concaved for a substantial portion of their extent and an outer end edge joining the outer ends of said side edges.

17. The method of making a felting needle,

which comprises providing a shaped wire having a body portion of substantially uniform cross gection provided with a lengthwise ridge of appreciable width having side walls Joined by an outer end wall'and projecting outward beyond the outline of the body, forming a transverse recess in the ridge thereby producing a spur having a work engaging surface, and pointing the end of the zvire which the work engaging surface of said spur aces.

18. The method of making a felting needle, which comprises providing a shaped wire having a body portion provided with a generally lengthwise ridge of appreciable width having side walls joined by an outer end wall, forming a transverse recess in said ridge thereby producing a spur having a work engaging surface, and pointing the end of the wire which the work engaging surface of said spur faces.

EDSON P. POS'I'ER. 

